A method and a mould assembly

ABSTRACT

A method of manufacturing a solid formulation product comprising steps of: positioning a platform into a cup comprising an open end comprising a skirt, such that the platform is at least partially received by the cup; then filing the cup with liquid formulation to a predetermined level such that the platform is at least partially submerged in the liquid formulation; solidifying the liquid formulation in the cup to form a solid formulation; once the solid formulation is formed, deforming then releasing the skirt.

This invention relates to a method of manufacturing a solid formulation product and a mould assembly for carrying out the same. More particularly, although not exclusively, the invention relates to a method and mould assembly for manufacturing a solid deodorant and/or antiperspirant formulation product suitable for refilling a reusable solid formulation product holder. However, the invention may also be applied to the manufacture of other solid formulation products in fields such as cosmetics and healthcare. For example, the solid formulation may be formulated to provide skin care or to facilitate topical application of a drug.

Deodorant formulations are capable of reducing body malodour following topical application and antiperspirant formulations are capable of reducing body perspiration following topical application. Topical application may be achieved by drawing the surface of a solid deodorant/antiperspirant formulation across the skin of the human body, particularly in the underarm regions.

Known products for topically applying a formulation to the skin of the human body, herein referred to as single-use sticks, comprise a holder which holds a solid formulation product, and which may be held by a user of the solid formulation stick.

In known single-use sticks, the holder comprises a container that surrounds the solid formulation product on all sides and some means, typically a platform and an associated spindle, designed to elevate the solid formulation product out of the container. The holder may be used until the solid formulation is exhausted and then disposed of in its entirety. Such known single-use sticks may be undesirable to consumers due to the quantity of single-use packaging material required for each product.

Alternative products for topically applying a formulation to the skin, herein referred to as refillable sticks, comprise a reusable holder to which a solid formulation product may be removably mounted. The refillable stick may be used until the solid formulation is exhausted, then the old solid formulation product may be removed and replaced with a new solid formulation product.

Such solid formulation products may be manufactured by filling a mould with a liquid formulation then solidifying the formulation to form a solid formulation within the mould. However, known methods for manufacturing such solid formulation products may result in the solid formulation becoming stuck in the mould. Following such manufacturing methods, testing has been performed on the removal of solid formulations from their respective moulds. It was found that high forces were required to remove the solid formulations and that there was a high risk the act of removing the solid formulation caused damage to the solid formulation due to the tensile forces involved.

According to a first aspect of the invention there is provided a method of manufacturing a solid formulation product comprising steps of: positioning a platform into a cup comprising an open end comprising a skirt, such that the platform is at least partially received by the cup; then filing the cup with liquid formulation to a predetermined level such that the platform is at least partially submerged in the liquid formulation; solidifying the liquid formulation in the cup to form a solid formulation; once the solid formulation is formed, deforming then releasing the skirt, wherein deforming the skirt comprises compression of the skirt along a compressible axis of the skirt which causes expansion of the skirt along an expandible axis of the skirt which is substantially normal to the compressible axis of the skirt.

By means of the invention a solid formulation product comprising a solid formulation and a platform embedded within the solid formulation may be manufactured. The platform may be attachable to a reusable holder in order to mount the solid formulation to the holder for use. Accordingly, the solid formulation product may be a solid formulation refill product suitable for refilling a refillable stick. Further, the step of deforming then releasing the skirt causes the cup to deform in shape (at least temporarily, depending on the elasticity or plasticity of the cup) which in turn causes the cup (which acts as a mould for the formulation) to separate, at least partially, from the solid formulation (at least temporarily).

The inventors hypothesize that, in known methods of manufacturing solid formulation products, a solid formulation may become stuck in the mould it was formed in due to one, or a combination, of adhesion, vacuum formation and capillary action. However, the separation of the cup from the solid formulation by means of the invention obviates the issues of adhesion, vacuum formation and/or capillary action. Testing has confirmed that the separation greatly reduces the removal forces required and lowers the risk of causing damage to the solid formulation during the removal process.

In some embodiments of the invention, the step of solidifying the liquid formulation in the cup may be carried out after filling the cup to the predetermined level such that the entire solidifying step is subsequent to the entire filling step. In other embodiments of the invention, the step of solidifying the liquid formulation in the cup may begin while further liquid formulation is still being added to the cup such that the filling step and the solidifying step overlap one another.

The step of deforming the skirt comprises compressing the skirt along a compressible axis of the skirt.

The step of compressing the skirt causes the skirt to deform such that the dimensions of the compressible axis are reduced in size. This step also causes the skirt to deform such that the dimensions along an extendable axis substantially normal to the compressible axis, are increased. Further, the cup may deform in shape similarly to the skirt. Deformation of the cup may cause it to separate, at least partially, from the solid formulation. For example, spaces may form between the cup and the solid formulation due to the second diameter of the cup increasing in size while a corresponding diameter of the solid formulation remains substantially the same.

In embodiments of the invention the skirt may be oval-shaped or obround-shaped in cross-section and the step of compressing the skirt along a compressible axis may comprise radially compressing the skirt such that a maximum diameter of the cross-sectional shape is reduced.

In such embodiments of the invention the maximum diameter is the largest diameter across the oval- or obround-shaped cross-section of the skirt. Accordingly, the cross-sectional shape may also comprise a minimum diameter which is the smallest diameter across the oval- or obround-shaped cross-section of the skirt.

If the cup is deformable such that its cross-sectional area remains constant, deformation of the skirt that causes a reduction of its maximum diameter will in turn cause an increase of its minimum diameter. Further, although the reduction of the maximum diameter may be small relative to the maximum diameter itself, the associated increase of its minimum diameter may be larger relative to the minimum diameter.

Therefore, radially compressing the skirt to reduce the dimensions of the skirt along its compressible axis may result in a compression of the solid formulation which is advantageously small relative to the maximum diameter. Further, radially compressing the skirt may also result in spaces forming between the solid formulation and the cup, which are advantageously large relative to the minimum diameter, because the dimensions along the extendible axis are increased while corresponding dimensions of the solid formulation remain substantially constant. In other words, the deformation may cause a relatively small compression of the solid formulation along the compressible axis but may result in relatively large spaces opening between the cup and the solid formulation due to the cup expanding in the along the extendible axis, normal to the compressible axis.

In other embodiments of the invention the skirt, and the cup, may be any suitable shape in cross-section. For example, the skirt may be circular cross-section.

In embodiments of the invention the platform may comprise a retaining structure, and the step of filing the cup with liquid formulation to a predetermined level comprises filling the cup such that the retaining structure is fully submerged in the liquid formulation.

In such embodiments of the invention, once the step of filling the cup with liquid formulation to the predetermined level is complete, liquid formulation may flow around and/or through the retaining structure. Therefore, once the step of solidifying the liquid formulation to form a solid formulation is complete, the retaining structure may be embedded in the solid formulation. The retaining structure may therefore facilitate retention of the solid formulation in contact with the platform.

In embodiments of the invention the platform may comprise an attachment element, and step of filing the cup with liquid formulation to a predetermined level comprises filling the cup such that the attachment element is not submerged in the liquid formulation.

In such embodiments of the invention, once the step of filing the cup with liquid formulation to a predetermined level is complete, the attachment element may be spaced apart from the liquid formulation. Subsequently, once the step of solidifying the liquid formulation to form a solid formulation is complete, the attachment element may be spaced apart from the solid formulation which may ensure that the attachment element is unobstructed from mating with a reusable holder, for example.

In embodiments of the invention the method may comprise a subsequent step of attaching a reusable holder to the attachment element.

A user may therefore hold the solid formulation via the reusable holder in order to draw the solid formulation over the skin, for example. The user may therefore avoid directly holding the solid formulation which may result in unwanted residue being left on the user's hands.

In embodiments of the invention the liquid formulation may be molten and may be solidified by cooling to below its melting point.

In such embodiments of the invention the solidifying step may be controlled via control of the cup and/or environmental temperature in order to lower the temperature of the molten liquid formulation below its melting point so that it solidifies. Further the temperature of the cup and/or environment may be configured to control the rate at which the liquid formulation solidifies.

In other embodiments of the invention the step of solidifying the liquid formulation may comprise increasing the pressure on it or may comprise a combination reducing temperature and increasing pressure.

In embodiments of the invention the method may comprise the further, subsequent, step of positioning a label over the solid formulation.

In such embodiments of the invention a label may be applied directly to the solid formulation product. Labelling the solid formulation product as part of its manufacturing process may reduce risk that the product is mislabelled or misdirected at a later stage of packaging or shipment.

In embodiments of the invention the method may comprise the further, subsequent, step of attaching a lid to the cup.

In such embodiments of the invention the solid formulation and platform may be sealed within the cup. Sealing the solid formulation may help to ensure that it maintains optimal chemical and physical properties during later process stages such as storage and shipment. For example, sealing the solid formulation may prevent the formulation from drying out.

According to a second aspect of the invention there is provided a mould assembly comprising a cup, which cup comprises an open end comprising a skirt, and a platform receivable within the cup; wherein the skirt is shaped such that when the platform is received within the cup a space is defined between the platform and the skirt.

By means of the invention the shape of the cup may readily be deformed by compressing the skirt wherein such a compression is possible due to the space between the skirt and the platform.

During the manufacturing of a solid formulation product, the platform may be positioned such that it is at least partially received by the cup, the cup may be filled with liquid formulation such that the platform is at least partially submerged and the liquid formulation may be solidified to form a solid formulation. In other words, the cup may act as a mould for the formation of a solid formulation that has the platform embedded within it.

Following formation of the solid formulation, the skirt may be compressed which may deform the shape of the cup and cause it to separate from the solid formulation. The separation of the cup from the solid formulation may obviate potential issues of adhesion, vacuum formation and/or capillary action between the solid formulation and the cup and allow the solid formulation to be removed from the cup with low risk of damage to the solid formulation.

In embodiments of the invention the cup may comprise any suitable material such as paper, cardboard, wood, metal or plastic. In some embodiments of the invention the cup may comprise recycled and/or recyclable material such as recycled polyethylene terephthalate (rPET) or recycled polypropylene (rPP) so that the solid formulation product may be manufactured sustainably.

In embodiments of the invention the cup may be deformable in any suitable way (i.e. resiliently, plastically or otherwise deformable) that allows the cup to deform and separate from the solid formulation when the skirt is deformed.

In some embodiments of the invention the cup may be resiliently deformable.

In such embodiments of the invention the cup may be deformed, via compression of the skirt for example, and may then return to its original shape.

In use, once a solid formulation formed within the cup has been separated from the cup by deforming the skirt, limited testing of some formulation indicates that it is very unlikely that the solid formulation will become stuck in the cup again. This is even true if the cup returns to its original shape, i.e. the shape in which the solid formulation was formed.

The cup may have a second use as packaging for the solid formulation in that the solid formulation, platform and cup may form a solid formulation product suitable for shipment and sale to retailers and/or consumers. The end user may remove the platform and solid formulation from the cup in order to attach the platform to a reusable holder in order to topically apply the solid formulation to the skin.

It may therefore be advantageous that the cup is resiliently deformable as, following deformation, the cup may return to its original shape. The original shape may be known, and further packaging and shipment processes may be based upon the known shape of the cup. For example, a plurality of solid formulation products may be packaged together for sale to consumers as a ‘multi-pack’. The multi-pack packaging may be designed to compactly hold the solid formulation products based on the known shape of the resiliently deformable cup.

In embodiments of the invention the cup may be oval-shaped or obround-shaped in cross-section.

In such embodiments of the invention the cross-sectional shape may comprise a maximum diameter of the oval or obround shape and a minimum diameter of the oval or obround shape. The maximum diameter may extend along a compressible axis and the minimum diameter may extend along an extendible axis.

If the cup is deformable such that its cross-sectional area remains constant, deformation of the skirt that causes a reduction of the maximum diameter which is small relative to the maximum diameter itself may, in turn, cause an increase of the minimum diameter which is larger relative to the minimum diameter. Therefore, in use, radially compressing the skirt to reduce its maximum diameter may result in a compression of the solid formulation (formed in the cup) which is advantageously small relative to the maximum diameter. Further, such a radial compression of the skirt may also result in spaces forming between the solid formulation and cup, which are advantageously large relative to the minimum diameter, because the minimum diameter is increased while a corresponding diameter of the solid formulation remains substantially constant. In other words, the deformation causes a relatively small compression of the solid formulation in the direction of the maximum diameter but results in relatively large spaces opening between the cup and the solid formulation due to the cup expanding in the direction of the minimum diameter.

Therefore, the cup being oval-shaped or obround-shaped in cross-section may advantageously improve the ability to separate the cup from the solid formulation when the cup is in use.

Further, the oval-shape or obround-shape may be determined such that a solid formulation formed in the cup is shaped to fit ergonomically against the underarm of a user.

Also, the oval-shape or obround-shape of the resulting solid formulation may exhibit higher resistance to shear forces in the direction of the maximum diameter which may be the same direction that a user would be most likely drag the solid formulation over the skin. Hence, the oval or obround cross-sectional shape of the cup may enhance the performance of a solid formulation formed within it.

In embodiments of the invention the platform may be oval-shaped or obround-shaped in cross-section.

In such embodiments the platform may fit complimentarily within the cup if the cup is also oval-shaped or obround-shaped in cross-section.

Further, if in use the platform is embedded in a solid formulation formed in the cup, the platform may exhibit better retention of the solid formulation in the direction of the maximum diameter which may be the same direction that a user would be most likely draw the solid formulation over the skin. Hence, the oval or obround cross-sectional shape of the platform may enhance the performance of a solid formulation formed around the platform.

In other embodiments of the invention the cup and the platform may each be any suitable shape in cross-section. For example, the cup and/or the platform may be circular in cross-section.

In embodiments of the invention the platform may comprise a retaining structure.

In such embodiments of the invention the retaining structure may be adapted such that liquid formulation is able to flow around and/or through the retaining structure as it is added to the cup. For example, the retaining structure may comprise one or more apertures through which the liquid formulation may flow. Therefore, when the liquid formulation is solidified, it solidifies around and/or within the retaining structure such that the retaining structure is embedded in the solid formulation.

Further, the retaining structure may be adapted such that, once embedded within the solid formulation, it retains the solid formulation in contact with the platform when the solid formulation is in use. For example, the retaining structure may be adapted such that retention of the solid formulation to the platform is resistant to shear forces applied to the solid formulation when a surface of the solid formulation is drawn over the skin of the user.

In embodiments of the invention the platform may comprise an attachment element.

In such embodiments of the invention the attachment element may be any suitable means for facilitating attachment of the platform to a reusable holder. For example, the attachment element may be a bayonet element engageable with a socket forming part of a reusable holder, or it may be a threaded protrusion engageable with a complimentarily threaded socket forming part of a reusable holder.

In use, a solid formulation may be formed in the cup with the platform embedded in it. The solid formulation may be removed from the cup prior to attaching the platform to a reusable holder via the attachment element. Alternatively, the platform may be attached to a reusable holder before the solid formulation is withdrawn from the cup. This may allow a user to hold the reusable holder while withdrawing the solid formulation from the cup and avoid touching the solid formulation.

In embodiments of the invention the mould assembly may comprise a label positionable within the cup.

The label may provide information useful for subsequent packaging and shipment processes, such as a product identification code. The label may also, or alternatively, provide useful information to a future consumer/user of the product, such as ingredients used for the solid formulation and allergy information.

In embodiments of the invention the mould assembly may comprise a lid removably attachable to the open end of the cup.

In such embodiments of the invention the lid may seal the contents of the cup which, in use, may include a solid formulation, the platform embedded in the solid formulation and a label placed over the solid formulation and platform, for example.

In such embodiments of the invention it may be particularly advantageous for the cup to be resiliently deformable as this may ensure that the open end of each cup is a consistent and reliable shape to allow attachment of the lid.

The invention will now be described by way of example only with reference to the accompanying drawings in which:

FIG. 1 is a schematic representation of a mould assembly according to an embodiment of the second aspect of the invention;

FIG. 2 is a schematic representation of a method according to an embodiment of the first aspect of the invention;

FIG. 3 is a schematic representation of a mould assembly according to another embodiment of the second aspect of the invention;

FIG. 4 is a further schematic representation of the mould assembly shown in FIG. 3 ;

FIG. 5 is a top view of the mould assembly shown in FIG. 3 ;

FIG. 6 is a schematic representation of a method according to another embodiment of the first aspect of the invention;

FIGS. 7 and 8 are schematic representations of a cup and a platform forming part of the mould assembly shown in FIG. 3 with a solid formulation;

FIG. 9 is schematic representations of the mould assembly shown in FIG. 3 with a solid formulation; and

FIG. 10 is a schematic representation of a method of using a solid formulation product manufactured using the method shown in FIG. 5 .

Referring initially to FIG. 1 , a mould assembly 12 comprises a cup 14 and a platform 20 receivable within the cup 14. The cup 14 further comprises an open end 16 comprising a skirt 18 shaped such that when the platform 20 is received within the cup 14 a space is defined between the platform 20 and the skirt 18. Additionally, the platform 12 comprises a retaining structure 22 and an attachment element 24.

In this embodiment of the invention the cup 14, open end 16, skirt 18 and platform 20 are each shaped such that the platform 20 may be positioned through the open end 16 to rest level with the skirt 18 without needing to be held to stop it from dropping further into the cup 14. This is achieved due to the change in circumference of the cup 14 as it transitions into the skirt 18, the changing circumference forms a ledge 19 that the platform 20 may balance on.

Referring now to FIG. 2 , a method of manufacturing a solid formulation product according to an embodiment of the invention is designated generally by the reference numeral 100. The method 100 comprises a positioning step 102, a filling step 103, a solidifying step 104 and a deforming step 105.

The method 100 may be used with any suitable mould assembly, and in one embodiment of the invention the mould assembly 12 of FIG. 1 is used to carry out the method. The method 100 is therefore described below with reference to the mould assembly 12.

The positioning step 102 comprises positioning a platform 20 into a cup 14 comprising an open end 16 comprising a skirt 18, such that the platform 20 is at least partially received by the cup 14.

The cup 14 may be any suitable size or shape to act as a mould for the formation of a solid formulation. The platform 20 may be any suitable size and shape so that it may, at least partially, be received by the cup 14 through the open end.

The filling step 103 follows the positioning step 102 and comprises filing the cup 14 with liquid formulation to a predetermined level, determined such that the platform 20 is at least partially submerged in the liquid formulation. In embodiments of the invention the liquid formulation may be a liquid deodorant formulation and/or a liquid antiperspirant formulation.

The solidifying step 104 involves solidifying the liquid formulation in the cup to form a solid formulation and may either be started as soon as liquid formulation is present in the cup or once the filling step is complete. In embodiments of the invention the solid formulation may be a solid deodorant formulation and/or a solid antiperspirant formulation.

Solidifying the liquid formulation may comprise reducing the temperature of the liquid formulation, increasing the pressure on the liquid formulation or adding an additive to the liquid formulation to cause it to solidify. For example, the liquid formulation may be molten and may be solidified by reducing its temperature below its melting point.

The deforming step 105 may be performed once the solid formulation is formed and comprises deforming then releasing the skirt 18 of the cup 14.

Deforming the skirt 18 may cause deformation of the cup 14 which may in turn cause the cup to separate from the solid formulation formed inside it. The separation of the cup 14 from the solid formulation may obviate potential issues such as adhesion, vacuum formation and/or capillary action which could otherwise cause the solid formulation to become stuck in the cup 14. Thus the deforming step 105 may reduce the likelihood of the solid formulation being damaged when it is removed from the cup 14.

Referring now to FIG. 3 , a mould assembly 112 comprises a cup 14 and a platform 20, similarly to the mould assembly 12 shown in FIG. 2 , and further comprises a label 26 and a lid 28. The label 26 is positionable within the cup 14 and is further positionable over the platform 20 such that the attachment element 24 extends through apertures 27 in the label 26.

The lid 28 is removably attachable to the open end 16 of the cup 14. In FIG. 4 , the lid 28 is attached to the open end 16, thereby forming a closure over the cup 14 and sealing the platform 20 and label 26 within the cup 14.

In this embodiment of the invention the cup 14 is resiliently deformable which may be advantageous as, following deformation, the cup 14 may return to its original shape. This means that, even following a deformation to the cup 14, the lid 28 may be attachable to the open end 16.

Both the cup 14 and the platform 20 are oval-shaped in cross-section. In FIG. 5 , the cross-section of the cup mould assembly 112 is shown and comprises a maximum diameter X and a minimum diameter Y.

Referring now to FIG. 6 , a method 200 of manufacturing a solid formulation product is similar to the method 100 shown in FIG. 1 except that it comprises further steps.

As well as the method 200 comprising a positioning step 202, a filling step 203, a solidification step 204 and a deforming step 205 that correspond respectively to steps 102, 103, 104 and 105 of method 100, the method 200 further comprises a preliminary step 201 carried out prior to the positioning step 202. The method 200 also comprises a labelling step 206 and a lidding step 207 each carried out subsequently to the deforming step 205.

The method 200 may be carried out using any suitable mould assembly and in one embodiment of the invention the mould assembly 112 of FIGS. 3 and 4 is used. The method 200 is therefore described below with reference to the mould assembly 112.

The preliminary step 201 comprises positioning the cup 14 in a puck 60, on a factory line for example.

The positioning step 202 comprises positioning the platform 20 into the cup 14 such that the platform 20 is at least partially received by the cup 14.

The filling step 203 comprises filling the cup 14 with a liquid formulation 32 to a predetermined level, determined such that the platform 20 is at least partially submerged in the liquid formulation 32. Further, the predetermined level, is determined such that the retaining structure 22 is fully submerged in the liquid formulation 32 but the attachment element 24 is not submerged in the liquid formulation 32.

The solidifying step 204 comprises solidifying the liquid formulation 32 to form a solid formulation 34 within the cup 14.

FIGS. 7 and 8 show the cup 14 with the solid formulation 34 formed within it and the platform 20 partially embedded in the solid formulation 34. In particular, due to the predetermined level to which the cup 14 is filled with the liquid formulation 32, the retaining structure 22 is fully embedded within the solid formation 34 whereas the attachment element 24 is spaced apart, and extends away, from the solid formulation 34.

The deforming step 205 comprises deforming then releasing the skirt 18. This may be possible due to a space 19 defined between the platform 20 and the skirt 18 (shown in FIGS. 7 and 8 ).

In particular, the deforming step 205 comprises radially compressing the skirt 18 along a compressible axis to reduce its maximum diameter X. This may cause the cup 14 to deform in shape which may include an expansion of the minimum diameter Y along an extendible axis. Meanwhile, the corresponding diameter of the solid formation 34 may not expand, or may not expand to the same degree, meaning that spaces may form between the solid formulation 34 and the cup 14. Such separation of the cup 14 from the solid formulation 34 may facilitate removal of the solid formulation 34 from the cup 14 with low risk of causing damage to the solid formulation 34.

The labelling step 206 comprises positioning a label 26 over the solid formulation 34.

Lastly, the lidding step 207 comprises attaching a lid 28 to the cup 14, specifically to the open end 16. The method 200 thereby uses each component of the mould assembly 112 to manufacture a solid formulation product 40.

For this step, it may be particularly advantageous that the cup 14 is resiliently deformable as this may ensure that the lid 28 is correctly attachable to the cup 14, even following the deforming step 205. For example, FIG. 9 shows that the lid 28 may adapted to fit precisely over the open end 16 such that, if the cup 14 were to be permanently deformed by the deforming step 205 it is possible that the lid 28 may not attach to the cup as intended. If the closure of the cup 14 failed, it is possible that the solid formulation 34 inside may deteriorate before it is used by the consumer.

Referring now to FIG. 10 , a solid formulation product such as the solid formulation product 40 manufactured according to the method 200 shown in FIG. 6 may be attached to a reusable holder 50 in order to refill a refillable stick 52. A method 300 of using the solid formulation product 40 comprises a first step 301, a second step 302, a third step 303 and a fourth step 304.

The first step 301 comprises removing the lid 28 from the cup 14. This reveals both the label 24 (which may provide information about the solid formulation such as its brand, ingredients and allergy information) and the attachment element 24.

The second step 302 comprises positioning the solid formulation product 40 in contact with the reusable holder 50. In particular, the attachment element 40 may be aligned with a complimentarily adapted feature forming part of the reusable holder 50, such as a socket with which the attachment element 24 is engageable.

The third step 303 comprises engaging the solid formulation product 40 with the reusable holder 50 via the attachment element 24. This may involve rotating the solid formulation product 40 through 90° relative to the reusable holder 50, for example.

The fourth step 304 comprises removing the cup 14 from the solid formulation 34 and platform 20, thereby revealing the solid formulation 34 for topical application to the skin. Earlier separation of the cup 14 from the solid formulation 34 during the method 200 (shown in FIG. 6 ) may facilitate the removal of the cup 14 with low risk of causing damage to the solid formulation 34.

A reusable cap (not shown) may then be attached to the reusable holder 52, over the solid formulation 34, to protect the solid formulation 34 between uses.

Accordingly, a solid formulation 34 may be mounted to a reusable holder 50 via a platform without the user needing to touch the solid formulation 34 with his or her hands. Further, the solid formulation product 40 may facilitate the repeated use of a refillable stick 52 which may be more sustainable than purchasing a new single-use stick each time the solid formulation is exhausted.

Preferences and options for a given aspect, feature or parameter of the invention should, unless the context indicates otherwise, be regarded as having been disclosed in combination with any and all preferences and options for all other aspects, features and parameters of the invention. For example, each step or feature of the method 200 (shown in FIG. 6 ) which is not explicitly included in the method 100 (shown in FIG. 1 ) may be regarded as having been disclosed in combination with the steps and features of the method 100. 

1. A method of manufacturing a solid formulation product comprising steps of: positioning a platform into a cup comprising an open end comprising a skirt, such that the platform is at least partially received by the cup; then filing the cup with liquid formulation to a predetermined level such that the platform is at least partially submerged in the liquid formulation; solidifying the liquid formulation in the cup to form a solid formulation; once the solid formulation is formed, deforming then releasing the skirt, wherein deforming the skirt comprises compression of the skirt along a compressible axis of the skirt which causes expansion of the skirt along an expandible axis of the skirt which is substantially normal to the compressible axis of the skirt.
 2. A method according to claim 1 wherein: the skirt is oval-shaped or obround-shaped in cross-section; and the step of compressing the skirt along a compressible axis comprises radially compressing the skirt such that a maximum diameter of the cross-sectional shape is reduced.
 3. A method according to claim 1 wherein: the platform comprises a retaining structure; and the step of filing the cup with liquid formulation to a predetermined level comprises filling the cup such that the retaining structure is fully submerged in the liquid formulation.
 4. A method according to claim 1 wherein: the platform comprises an attachment element; and the step of filing the cup with liquid formulation to a predetermined level comprises filling the cup such that the attachment element is not submerged in the liquid formulation.
 5. A method according to claim 4 comprising a subsequent step of attaching a reusable holder to the attachment element.
 6. A method according to claim 1 wherein the liquid formulation is molten and is solidified by cooling to below its melting point.
 7. A method according to claim 1 comprising a subsequent step of attaching a lid to the cup.
 8. A mould assembly comprising a cup, which cup comprises an open end comprising a skirt, and a platform receivable within the cup; wherein the skirt is shaped such that when the platform is received within the cup a space is defined between the platform and the skirt.
 9. A mould assembly according to claim 8 wherein the cup is resiliently deformable.
 10. A mould assembly according to claim 8 wherein the cup is oval-shaped or obround-shaped in cross-section.
 11. A mould assembly according to claim 10 wherein the platform is oval-shaped or obround-shaped in cross-section.
 12. A mould assembly according to claim 8 wherein the platform comprises a retaining structure.
 13. A mould assembly according to claim 8 wherein the platform comprises an attachment element.
 14. A mould assembly according to claim 8 comprising a lid removably attachable to the open end of the cup. 